Radiator, charge air cooler and condenser mounting method

ABSTRACT

A method for mounting a cooling assembly for use in a motor vehicle, with the cooling system including a radiator assembly, a charge air cooler, and a condenser. The radiator assembly is mounted to a chassis of the motor vehicle, the charge air cooler is mounted to the radiator assembly, and the condenser is mounted to the charge air cooler so as to dispose the radiator assembly, charge air cooler and condenser in series flow relationship with one another. The radiator assembly includes a frame having two generally U-shaped portions, and a radiator, or heat exchanger, disposed within and mounted to the frame. A first lateral end portion of the radiator is rigidly attached to one of the U-shaped portions of the frame. The opposite lateral end portion of the radiator is resiliently mounted to the other U-shaped portion of the frame, which is accomplished by coupling a pair of leaf springs to the radiator and the frame. The charge air cooler includes a pair of laterally spaced and downwardly extending pins which engage compressible grommet assemblies disposed in the holes of mount brackets attached to the radiator assembly. Compressible grommet assemblies are also disposed between a pair of laterally spaced upper mount flanges attached to the charge air cooler and the mating mount brackets attached to the radiator. One end of the condenser is laterally fixed relative to the charge air cooler, while the opposite end of the condenser includes a pair of vertically spaced pins which engage compressible grommet assemblies disposed within the holes of mount brackets attached to the charge air cooler, so as to accommodate differential lateral thermal growth between the condenser and the charge air cooler.

CROSS REFERENCES

The subject application is related to concurrently filed and commonlyassigned U.S. patent applications Ser. No. 08/554,958 now U.S. Pat. Nos.5,570,738 and 08/554,959 now U.S. Pat. No. 5,566,748 entitled,respectively, "Radiator Assembly For Use In A Motor Vehicle" and "ChargeAir Cooler/Condenser Sub-Assembly For Use In A Motor Vehicle".

BACKGROUND OF THE INVENTION

1.0 Field of the Invention

The present invention relates to motor vehicle cooling systems and, moreparticularly, to a method for mounting a radiator, a charge air coolerand a condenser for use in heavy vehicles such as trucks.

2.0 Related Art

Motor vehicles, including heavy vehicles such as trucks, utilize aradiator assembly to eliminate waste heat from the internal combustionengine of the vehicle. The waste heat is a by-product of the internalcombustion process and must be removed to allow steady state operationof the vehicle powertrain system. The radiator assembly includes a framemounted to the chassis of the motor vehicle and a radiator mounted tothe frame and comprising a core, or heat exchanger, and inlet and outletmanifolds or header tanks which communicate with the core. The radiatorcore comprises a plurality of tubes and fins, typically disposed inalternating laterally extending rows, with the tubes communicating withthe inlet and outlet tanks so as to provide a flowpath for an enginecoolant fluid, particularly water or glycol. Ambient cooling air isforced across the tubes and fins during operation of the vehicleresulting in heat transfer from the heated engine coolant flowing insidethe core tubes to the ambient air stream. The temperature of the coolantfluid is typically controlled by a thermostat but can still vary by20-40° F. during normal operation of the vehicle due to engine load,ambient conditions, altitude and vehicle speed. The mean temperature ofthe radiator is therefore not constant, while the temperature of theframe remains relatively constant, corresponding approximately toambient temperature. Known radiator cores are typically rigidly mountedto the radiator frame, thereby failing to accommodate the differentialexpansion of the core and frame. For instance, in one known apparatus,the radiator frame includes upper and lower members, with each fixedlyattached at opposite ends to the radiator inlet and outlet tanks,thereby causing the tanks to be structural load-carrying members. Insome instances, this arrangement, coupled with the differential thermalexpansion of the radiator core tubes and the frame, has resulted in tubedistress, in the form of cracks, at a location proximate one of thetanks.

The engines of heavy vehicles such as trucks may be turbocharged andaccordingly such vehicles may include a charge air cooler (CAC) forpurposes of cooling the turbocharged engine intake air before the airenters the engine for the combustion process. The intake air is heatedduring the turbocharger compression process and must be cooled by theCAC to satisfy engine durability and performance requirements. The CACtypically includes inlet and outlet manifolds and a core assembly havinga plurality of alternating tubes and fins, with ambient air forcedacross the tubes so as to cool the heated intake air flowing through thetubes during operation of the vehicle. The temperature of theturbocharged intake air varies widely as a function of engine load,ambient conditions, altitude and vehicle speed. Consequently, as withthe radiator, the mean temperature of the CAC is not constant.

Heavy vehicles also typically include a refrigerant condenser assemblywhich receives high pressure, superheated refrigerant gas from therefrigerant compressor and condenses the gas into a high pressure liquidfor expansion and cooling of the vehicle cab. The superheated vapor isfirst cooled to its saturation point at the existing operating pressureand is then condensed isothermally into the high pressure liquid. Thehigh pressure liquid is then sub-cooled to a temperature below thecondensing temperature. The temperatures within the condenser varywidely due to vehicle thermal load, engine speed, vehicle speed andambient conditions.

Heat exchangers such as the radiator, CAC and condenser are surface areadependent, requiring substantial surface area to produce the requiredtemperature reduction of the fluids being cooled. The radiator, CAC andcondenser may be mounted in a parallel flow relationship, so as tomaximize the airflow through each unit, as shown in FIG. 1 of U.S. Pat.No. 5,095,882, with respect to a radiator assembly and a CAC, oraftercooler. However, such a parallel flow arrangement is unnecessarilycumbersome, particularly in small engine compartments. Accordingly, incertain applications it is desirable to arrange the various heatexchangers in a stacked, or series flow arrangement. While thisarrangement alleviates the spatial problem associated with the parallelflow mounting scheme, known systems of this type fail to accommodate thedifferential thermal expansion which may occur between each adjacentpair of heat exchangers, due to the varying temperature profiles of theradiator, CAC, and condenser. For instance, the inventor is not aware ofany known systems which accommodates differential thermal expansionbetween a condenser and a CAC mounted in series. Failure to accommodatethis differential thermal expansion can result in relatively largethermal stresses, which in turn can cause premature component failures.

SUMMARY

Accordingly, the present invention is directed to a method for mountinga cooling assembly for use in a motor vehicle, with the cooling assemblyincluding a radiator assembly, a charge air cooler, and a condenser.According to a preferred embodiment of the present invention, the methodcomprises the steps of rigidly mounting a first lateral end portion of aradiator of the radiator assembly to a support structure of the radiatorassembly and resiliently mounting a second, opposite, lateral endportion of the radiator to the support structure so as to accommodatelateral thermal growth of the radiator relative to the supportstructure. The method further includes the step of mounting the supportstructure to a chassis of the motor vehicle.

In other preferred embodiments, the foregoing method steps may befurther defined, and the method may include additional steps as follows.The step of resiliently mounting the second lateral end portion of theradiator to the support structure comprises the step of coupling atleast one spring member to the support structure and the second lateralend portion of the radiator. The support structure of the radiatorassembly includes first and second generally U-shaped portions and thestep of resiliently mounting the second lateral end portion of theradiator may further include the steps of: attaching first and secondmulti-pronged mount brackets to upper and lower members, respectively,of one of the first and second U-shaped portions of the supportstructure; attaching a first end of a first spring member to one of themulti-pronged U-shaped mount brackets and a second end of the firstspring member to the second lateral end portion of the radiator;attaching a first end of a second spring member to the other of themulti-pronged mount brackets and a second end of the second springmember to the second lateral end portion of the radiator. The method mayfurther include the step of preloading each of the first and secondspring members, which may comprise leaf springs. The step of preloadingthe first and second leaf springs comprises the step of adjusting aposition of each of the multipronged brackets relative to the U-shapedportion of the support structure to which they are attached. The step ofrigidly mounting the first lateral portion of the radiator comprises thestep of fastening the first lateral portion of the radiator to the otherof the first and second U-shaped portions of the support structure ofthe radiator assembly. The method may further include the step ofconnecting the first and second U-shaped portions of the supportstructure of the radiator assembly.

The method may further include the steps of: mounting the charge aircooler to the radiator assembly so as to accommodate differentialthermal growth between the charge air cooler and the radiator assemblyand so as to dispose the charge air cooler in series flow relationshipwith the radiator assembly; and mounting the condenser to the charge aircooler so as to accommodate at least differential lateral thermal growthbetween the condenser and the charge air cooler and so as to dispose thecondenser in series flow relationship with the charge air cooler and theradiator assembly.

The step of mounting the charge air cooler to the radiator assemblycomprises the steps of: attaching a pair of laterally spaced, lowermount brackets to the radiator assembly, wherein each of the lower mountbrackets includes a generally horizontally extending portion and a holeformed therein; obtaining a first pair of compressible grommetassemblies; positioning one of the first pair of compressible grommetassemblies in each of the lower mount bracket holes; attaching a pair ofdownwardly extending and laterally spaced pins to the charge air cooler;and inserting each of the pins through one of the first pair ofcompressible grommet assemblies and a corresponding one of the laterallyspaced lower mount brackets so that the charge air cooler rests on thefirst pair of compressible grommet assemblies. The step of mounting thecharge air cooler may further comprise the steps of: attaching a pair oflaterally spaced, upper mount brackets to the radiator assembly, whereineach of the upper mount brackets includes a laterally facing portion anda hole formed therein; obtaining a second pair of compressible grommetassemblies; disposing one of the second pair of compressible grommetassemblies in each of the upper mount bracket holes; attaching a pair oflaterally spaced, upper mount flanges to the charge air cooler, whereineach of the mount flanges includes a mount hole formed therein which isaligned with the hole of one of the upper mount brackets; inserting athreaded fastener through each of the upper mount flange holes and thecorresponding one of the second pair of compressible grommet assemblies;and securing the threaded fastener so as to apply a clamp load to theupper mount flanges, the second pair of compressible grommet assembliesand the upper mount brackets. Each of the first pair of compressiblegrommet assemblies comprises a nylon sleeve having a generallycylindrical portion disposed about one of the downwardly extending pinsand an elastomeric grommet coaxially disposed about the generallycylindrical portion of the nylon sleeve. Each of the second pair ofcompressible grommet assemblies comprises a generally cylindricalmetallic sleeve disposed about one of the threaded fasteners and alaterally extending elastomeric grommet coaxially disposed about themetallic sleeve.

The step of mounting the condenser to the charge air cooler comprisesthe steps of: connecting a pair of vertical spaced and generallyhorizontally extending pins to a first lateral end portion of thecondenser; attaching a pair of vertically spaced pin-receiving mountmeans to the charge air cooler, wherein each of the mount means isaligned with one of the pins; disposing a compressible grommet assemblywithin a hole formed in each of the mount means; inserting each of thepins through one of the grommet assemblies and the hole of thecorresponding one of the mount means. The step of mounting the condenserfurther includes the following steps: attaching a first pair ofvertically spaced mount brackets to the condenser, wherein the firstpair of mount brackets is laterally spaced from the pins; attaching asecond pair of vertically spaced mount brackets to the charge aircooler, wherein the first and second pairs of vertically spaced mountbrackets are aligned with one another; and fastening each of the firstpair of mount brackets to an aligned one of the second pair of mountbrackets.

The charge air cooler includes a core and a pair of end manifoldsattached to opposite lateral ends of the core and the pair of verticallyspaced pin-receiving mount means may comprise first and secondvertically spaced mount brackets and the step of attaching the pair ofvertically spaced pin-receiving mount means may comprise the steps of:attaching a first one of the mount brackets to an upper surface of thecore of the charge air cooler; and attaching a second one of the mountbrackets to a lower surface of the core of the charge air cooler. Inthis embodiment, the step of connecting the pins to the first lateralend portion of the condenser includes the steps of: attaching a firstmount bracket to an upper end of the first lateral end portion of thecondenser; attaching a second mount bracket to a lower end of the firstlateral end portion of the condenser; and attaching each of thegenerally horizontally extending pins to one of the mount brackets.Alternatively, the pair of vertically spaced pinreceiving mount meansmay comprise first and second vertically spaced mount flanges and thestep of attaching the pair of vertically spaced pin-receiving mountmeans may comprise the step of: casting the first and second verticallyspaced mount flanges and one of the end manifolds of the charge aircooler as an integral unit. In this embodiment, the step of connectingthe pair of vertically spaced and generally horizontally extending pinscomprises the step of directly attaching the pins to the first lateralend portion of the condenser.

A main advantage of the method of the present invention is thearrangement of cooling system components in a spatially efficientmanner, which accommodates relative thermal growth between adjacentpairs of the stacked components.

BRIEF DESCRIPTION OF THE DRAWINGS

The aforementioned advantage, as well as the method steps and otheradvantages of the present invention, will become more apparent fromsubsequent description of the preferred embodiments when taken inconjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of an internal combustion engine of a motorvehicle incorporating the cooling system of the present invention;

FIG. 2 is a schematic flow diagram of the cooling system shown in FIG.1;

FIG. 3 is a front elevational view illustrating the condenser, chargeair cooler and radiator assembly of the cooling system of the presentinvention;

FIG. 4 is a side elevational view illustrating the condenser, charge aircooler and radiator assembly shown in FIG. 3;

FIG. 5 is a plan view illustrating the condenser, charge air cooler andradiator shown in FIGS. 3 and 4;

FIG. 6 is a fragmentary front elevational view illustrating the mountingof the radiator assembly to the chassis of the motor vehicle;

FIG. 7 is a view taken along line 7--7 in FIG. 6;

FIG. 8 is a view taken along line 8--8 in FIG. 6;

FIG. 9 is a front elevational view illustrating the support frame of theradiator assembly of the present invention;

FIG. 10 is a view taken along line 10--10 in FIG. 5;

FIG. 11 is a view taken along line 11--11 in FIG. 10;

FIG. 12 is a view further illustrating the radiator assembly, leafspring mounting bracket shown in FIGS. 10 and 11;

FIG. 13 is a fragmentary front elevational view of the condenser, chargeair cooler and radiator assembly of the present invention;

FIG. 14 is a fragmentary side elevational view illustrating thecondenser, charge air cooler and radiator assembly of the presentinvention;

FIG. 15 is an enlarged fragmentary side elevational view, partially incrosssection, further illustrating the method of mounting the condenserto the charge air cooler and the charge air cooler to the radiatorassembly;

FIG. 16 is an enlarged front elevational view, partially incross-section, further illustrating the method of mounting the condenserto the charge air cooler;

FIG. 17 is a front elevational view illustrating the cooling system ofthe present invention according to an alternative embodiment;

FIG. 18 is a side elevational view illustrating the alternative coolingsystem shown in FIG. 17.

DETAILED DESCRIPTION

Referring now to the drawings, FIG. 1 is a perspective view illustratingan internal combustion engine 10 of a motor vehicle incorporating acooling system, indicated generally at 12, according to the presentinvention. Cooling system 12 includes a condenser 14 (not shown in FIG.1), a charge air cooler 16 and a radiator assembly 18 which areillustrated schematically in the flow diagram of FIG. 2. As shown inFIGS. 1 and 2, the condenser 14, charge air cooler 16 and radiatorassembly 18 are disposed in series flow relationship with one anotherand are mounted forward of a fan 20 of engine 10. During the operationof engine 10, the suction action of fan 20 forces ambient air 22 to bedrawn through, in succession, condenser 14, charge air cooler 16 andradiator assembly 18. Additionally, the flow of ambient air 22 isassisted by the forward motion of the associated motor vehicle. Duringoperation of engine 10, condenser 14 receives a high pressure,superheated refrigerant gas from a refrigerant compressor, indicatedgenerally at 24, of an air conditioning system used to cool thepassenger compartment of the associated motor vehicle, via conventionalconduits as indicated by flow arrows 26. The superheated vapor flowingthrough condenser 14 is first cooled to its saturation point by ambientair 22 at the existing operating pressure of the vapor and is thencondensed isothermally by the ambient air 22 into a high pressure liquidwhich returns to compressor 24 via conventional conduits as indicated byflow arrows 28. According to a preferred embodiment, engine 10 is usedwith a heavy vehicle such as a truck and includes a turbocharger,indicated generally at 30, for purposes of turbocharging the intake airof engine 10. The intake air is heated during the turbochargercompression process and must be cooled to satisfy engine durability andperformance requirements. This is accomplished by routing the airdischarging from the turbocharger 30 to the charge air cooler 16 viaconventional conduits, as indicated by flow arrows 32, where the heatedintake air is cooled by ambient air 22 flowing through charge air cooler16. The intake air is then routed from the charge air cooler 16 to anintake manifold, indicated generally at 34, of engine 10 viaconventional conduits as indicated by flow arrows 36. Engine 10 produceswaste heat as a byproduct of the internal combustion process, which mustbe removed to allow steady state operation of engine 10. The eliminationof this waste heat is accomplished by radiator assembly 18, with coolantfluid, typically water or glycol, routed from engine 10 to radiatorassembly 18 via conventional conduits as depicted by flow arrow 38,where the coolant fluid is cooled by ambient air 22 as it flows throughthe radiator assembly 18. The coolant fluid then discharges fromradiator assembly 18 and is returned, via conventional conduits toengine 10 as depicted by flow arrows 40.

The condenser 14, charge air cooler 16 and the radiator assembly 18 areillustrated in detail in FIGS. 3-5 which correspond to front and sideelevation views and a plan view, respectively. As shown in FIG. 3-5,condenser 14 includes a central core, or heat exchanger 42 and generallyvertically end manifolds 44 and 46 attached to opposite lateral ends ofthe core 42. Core 42 includes a plurality of laterally extending tubes48, which are substantially parallel to one another, with each of thetubes 48 being in fluid flow communication with both of the endmanifolds 44 and 46. The core 42 of condenser 14 further includes aplurality of fins 50 having a serpentine, or corrugated shape (not shownfor ease of illustration), which extend laterally across core 42. Tubes48 and fins 50 are interdigitated with one another. End manifold 44includes an upper inlet fitting 52 which is effective for receiving thesuperheated refrigerant gas from the refrigerant compressor 24, with thegas flowing through tubes 48 between manifolds 44 and 46. Condenser 14may comprise a conventional 2-pass condenser, or alternatively, maycomprise other conventional types such as a 4-pass condenser, with thenumber of passes determined by appropriate dividers (not shown) withinend manifolds 44 and 46. The superheated refrigerant gas is first cooledto its saturation point at the existing operating pressure and is thencondensed isothermally into the high pressure liquid which exits throughan outlet fitting 54 attached to a lower end of the end manifold 44, andthen returns to the refrigerant compressor 24. The temperature withinthe condenser vary widely due to the speed of engine 10, the speed andthermal load of the associated motor vehicle, and ambient conditions. Ina preferred embodiment, the various components of condenser 14 areconstructed of aluminum, but suitable alternative metals may also beutilized. The charge air cooler 16 includes a central core, or heatexchanger 56, an inlet end manifold 58 attached to core 56, and anoutlet end manifold 60 which is also attached to core 56. Core 56includes a plurality of laterally extending tubes 62, which aresubstantially parallel to one another, and which are in fluid flowcommunication with the end manifolds 58 and 60. Core 56 further includesa plurality of laterally extending fins 64, each having a serpentine orcorrugated shape (not shown for ease of illustration), which areinterdigitated, or disposed in vertically alternating relationship withtubes 62. Inlet manifold 58 includes a inlet port 66 which is effectivefor receiving the heated intake air from turbocharger 30 duringoperation of engine 10. The heated intake air then flows through tubes62, where it is cooled by the ambient air 22, to the outlet manifold 60.The intake air then discharges through an outlet port 68 of manifold 60and then flows to the intake manifold 34 of engine 10. The temperatureof the turbocharged intake air entering inlet manifold 58 varies widelyas function of the thermal load of engine 10, ambient conditions,altitude and the speed of the associated motor vehicle. Consequently,the mean temperature of charge air cooler 16 is not constant. Theradiator assembly 18 includes a frame 70 and a radiator 72 disposedwithin and mounted to frame 70. The radiator 72 includes a central core,or heat exchanger 74, and first and second lateral end portions, or endmanifolds 76 and 78 (best seen in FIG. 10), respectively, which areattached to the radiator core 74. Core 74 includes a plurality oflaterally extending tubes 80, which are substantially parallel to oneanother, and which are in fluid flow communication with the endmanifolds 76 and 78 of radiator 72. Radiator 72 further includes aplurality of laterally extending fins 82 having a serpentine, orcorrugated shape (not shown for ease of illustration) which areinterdigitated with tubes 80. The radiator 72 further includes an inlettube 84 which communicates with the end manifold 78 of radiator 72 andis effective for receiving coolant fluid, such as water or glycol, fromengine 10. Radiator 72 also includes an outlet tube 86 whichcommunicates with the outlet end manifold 76. The engine coolant fluidflows through inlet tube 84 into end manifold 78 and then through tubes80, where it is cooled by ambient air 22, and then to outlet manifold76. The engine coolant fluid then discharges through the outlet tube 86and is returned to engine 10. Although the temperature of the enginecoolant fluid is typically controlled by a thermostat, the coolant fluidtemperature may still vary by about 20-40° F. during normal operation ofthe motor vehicle due to the thermal load of engine 10, ambientconditions, altitude and the speed of the motor vehicle. Due to thewidely varying temperature profiles of the condenser 14, charge aircooler 16 and the radiator 72 of radiator assembly 18, it is necessaryto accommodate differential thermal expansion the condenser 14 relativeto the charge air cooler 16, thermal expansion of condenser 16 relativeto the radiator assembly 18, and thermal expansion of radiator 72relative to radiator frame 70, so as to avoid hardware distress causedby large thermal stresses. This is accomplished by the novel mountingmethod of the present invention, as discussed subsequently detail.

Referring now to FIGS. 6-9, additional structural features of radiatorassembly 18, as well as the method for mounting radiator assembly 18 tothe motor vehicle, are illustrated and discussed in greater detail. Asshown in FIG. 9, the frame 70 of radiator assembly 18 includes first andsecond generally U-shaped portions 88A and 88B, respectively, which aresubstantially mirror images of one another. Portions 88A and 88B, have agenerally U-shaped cross section as shown in FIGS. 7 and 8. Portion 88Aincludes an upper, generally horizontally extending member 90A, a lower,generally horizontally member 92A, and a generally vertically extendingmember 94A interconnecting and attached to members 90A and 92A.Similarly, the U-shaped portion 88B includes upper and lower generallyhorizontally members 90B and 92B, respectively, and a generallyvertically extending member 94B interconnecting and attached to members90B and 92B. Portions 88A and 88B are connected to one another by a pairof generally U-shaped connecting members 96 of frame 70. An upper one ofthe connecting members 96 is attached to members 90A and 90B of portions88A and 88B, respectively, by conventional fasteners such as bolts 98.Similarly, the lower one of the connecting members 96 is attachedmembers 92A and 92B of portions 88A and 88B, respectively, by bolts 98.As shown in FIG. 7, with respect to member 92B and the lower one of themembers 96, each of the bolts 98 is threaded into a threaded insert 100captured within an anti-rotation slot 102 formed in one of theconnecting members 96. The frame 70 further includes a doubler plate 104which is fastened to members 92A and 92B and the lower one of connectingmembers 96 by bolts 98. Radiator assembly 18 further includes a pair ofchassis mount plates 106, with each of the plates 106 being secured toframe 70 by a mount bolt 108, an elastomeric isolator 110 and a nut 112.Each isolator 110 has a first portion 111 disposed between frame 70 andone of the plates 106. Each of the bolts 108 includes a head portion 114which is captured within an anti-rotation slot 116 formed in the lowerone of the connecting members 96. Each of the bolts 108 passes through ahole formed in the corresponding one of isolators 110, extends belowplate 106 and is secured with one of the nuts 112. Each of the mountplates 106 is fastened to a cross-member 118 of the motor vehiclechassis by conventional fasteners such as bolts 120, so as to mountframe 70 to chassis cross-member 118. Radiator assembly 18 furtherincludes a pair of laterally spaced tie-rod brackets 122 which areattached by conventional means, such as welding, to frame 70. A firstone of the brackets 122 is welded to member 90A of the U-shaped portion88A of frame 70, and the second mount bracket 122 is welded to themember 90B of the U-shaped portion 88B of frame 70. An elastomericisolator 124 is disposed within a hole formed in each of the brackets122. A pair of tie rods (not shown) are secured at an upper end thereofto the brackets 122 and to the motor vehicle chassis, for purposes ofmounting frame 70 to the motor vehicle chassis. The use of the lowerelastomeric isolators 110 and the upper elastomeric isolators 124,isolates frame 70 from mechanical vibration loads during the operationof the motor vehicle.

FIGS. 10-12 illustrate the apparatus and method steps regarding themounting of the radiator 72 to the frame, or support structure 70 ofradiator assembly 18. A first lateral end portion of radiator 70,comprising end manifold 76, is rigidly mounted to frame 70, whereas asecond lateral end portion of radiator 70, comprising the end manifold78, is resiliently mounted to frame 70 so as to accommodate lateralthermal growth of radiator 72 relative to the frame, or supportstructure 70. Radiator assembly 18 includes a first pair of verticallyspaced nuts 126 which are brazed within indentations formed in the endmanifold 76 and a pair of threaded studs 128 having a first end brazedwithin one of the nuts 126 and a second threaded end. Each of the studspasses through a hole formed in a metallic spacer 130 and a hole formedin the generally vertically extending member 94A of frame 70. Each stud128 is then secured by a nut 132 so as to rigidly mount the end manifold76 of radiator 72 to frame 70. The step of resiliently mounting thesecond lateral portion, or end manifold 78 of radiator 72 to frame 70includes the step of coupling a pair of vertically spaced spring members134 to the end manifold 78 and the U-shaped portion 88B of frame 70.Radiator assembly 18 includes a pair of vertically spaced, multi-prongedmount brackets 136 having a plurality of prongs, or flanges 138. Anupper one of the mount brackets 136 is disposed within the U-shapedportion 88B of frame 70, with each of the three prongs 138 fastened tomember 90B via bolts 140 which each engage a threaded boss 142 formed oneach of the prongs 138 of bracket 136. Each of the bolts 140 passthrough slotted holes 144 formed in the U-shaped portion 88B. The lowerone of the mount brackets 136 is similarly attached to the lower member92B of Ushaped portion 88B of frame 70. Radiator assembly 18 furtherincludes a second vertically spaced pair of the nuts 126 brazed withinindentations formed in the end manifold 78 and a pair of studs 146. Eachof the studs 146 includes a first end brazed within one of the nuts 126and a second threaded end. Each of the leaf springs 134 is fastened at afirst end thereof to one of the mount brackets 136 via a pair of rivets148, so as to couple each of the leaf springs 134 to the U-shapedportion 88B of frame 70. Each leaf spring 134 is coupled to end manifold78 by attaching a second, opposite end of each spring 134 to the endmanifold 78 via one of the studs 146 which are secured with nuts 150.The use of slotted holes 144 formed in the U-shaped member 88B permitsthe position of each of the mount brackets 136 to be adjusted laterallyrelative to member 88B. This is important as it permits each of the leafsprings 134 to be preloaded laterally.

Referring now to FIGS. 13-16, the apparatus and method for mounting thecharge air cooler 16 to the radiator assembly 18 and for mounting thecondenser 14 to the charge air cooler 16, is illustrated and discussedin further detail. A pair of laterally spaced, lower mount brackets 152are attached to the frame 70 of radiator assembly 18, by conventionalmeans such as welding. One of the brackets 152 is attached to thevertical member 94A of the U-shaped portion 88A of frame 70, while theother bracket 152 is attached to the vertical member 94B of the U-shapedportion 88B of frame 70. Each of the brackets 152 includes a generallyhorizontally extending portion, or flange 154 having a hole 156 formedtherein. A pair of downwardly extending and laterally spaced pins 158are attached to the charge air cooler 16, with the lateral spacingbetween pins 158 being substantially equal to the spacing between holes156 of brackets 152. A compressible grommet assembly 160 is positionedin each of the two lower mount bracket holes 156. Each of the grommetassemblies 160 includes a nylon insert 162 having a generallycylindrical portion 164. Grommet assembly 160 further includes a grommet166 made of an elastomeric material which includes a central holetherein and is disposed coaxially about the cylindrical portion 164 ofinsert 162. The nylon insert 162 is preferably molded together withgrommet 166 so as to form a unitary construction of grommet assembly160. Each of the pins 158 of the charge air cooler 16 is insertedthrough one of the grommet assemblies 160 and the corresponding lowermount bracket 154 so that charge air cooler 16 rests on the grommetassemblies 160. A pair of laterally spaced, upper mount brackets 168 isattached to frame 70 of radiator assembly 18 by conventional means, suchas welding. A first one of the brackets 168 is attached to the verticalmember 94A of the U-shaped portion 88A of frame 70, while the otherbracket 168 is attached to the vertical member 94B of the U-shapedportion 88B of frame 70. Each of the brackets 168 includes a laterallyfacing portion 170 having a generally horizontally extending hole 172formed therein. A pair of laterally spaced, upper mount flanges 174 areattached to the charge air cooler 16 by conventional means, such aswelding. Each of the mount flanges 174 includes a mount hole 176 formedtherein, with the hole 176 of each mount flange 174 being aligned withthe hole 172 of one of the upper mount brackets 170. A compressiblegrommet assembly 178 is disposed in each of the upper mount bracketholes 172. Each of the grommet assemblies 178 includes a generallycylindrical metallic sleeve 180 and a grommet 182 made of an elastomericmaterial. Grommet 182 includes a central hole therein and is disposedcoaxially about the metallic sleeve 180. Each grommet assembly 178further includes a pair of metallic washers 184, each having a holeformed therein, with the washers 184 being disposed on opposite lateralends of grommet 182. Washers 184 and sleeve 180 are preferably moldedtogether with grommet 182 so as to form a unitary construction ofgrommet assembly 178. A threaded fastener 186, comprising a conventionalbolt, is inserted through each of the upper mount flange holes 176 andthe corresponding ones of the grommet assemblies 178 and is secured witha nut 188 so as to apply a clamp load to each of the upper mount flanges174, the corresponding ones of grommet assemblies 178 and upper mountbrackets 168.

The mounting of the condenser 14 to the charge air cooler 16 may befurther illustrated with reference to FIGS. 13 and 16 and the followingdiscussion. A pair of vertically spaced and generally horizontallyextending pins 190 are connected to a first lateral end portion,comprising the end manifold 46, of condenser 14. Pins 190 are connectedto the end manifold 46 by attaching a pair of vertically spaced mountbrackets 192 to an upper end 191 and a lower end 193 of end manifold 46by conventional means, such as welding, and attaching one of the pins190 to each of the brackets 192. A pair of vertically spacedpin-receiving mount means or mount structures 194, which comprise a pairof vertically spaced mount brackets in the embodiment shown in FIGS. 13and 16, are attached to the charge air cooler 16. One of the brackets194 is attached to a lower surface 196 of the charge air cooler 16 whilethe other bracket 194 is attached to an upper surface 198 of the chargeair cooler 16. Each of the brackets 194 includes a vertically extendingportion with a hole 200 formed therein, with each of the holes 200 beingaligned with one of the pins 190. One of the grommet assemblies 160,described previously, is disposed within each of the holes 200 of mountbrackets 194. Each of the pins 190 is inserted through one of thegrommet assemblies 160, with each of the pins 190 being free to slidelaterally within the nylon inserts 162 of the grommet assemblies 160.Accordingly, end manifold 46 of condenser 14 may move laterally relativeto charge air cooler 16. A pair of vertically spaced mount brackets 202are attached to condenser 14, with brackets 202 being laterally spacedfrom mount brackets 192 as shown in FIG. 13. A pair of mating,vertically spaced mount brackets 204 are attached to the charge aircooler 16, by conventional means such as welding, and are aligned withbrackets 202. Brackets 202 and 204 are fastened to one another by bolts206 and nuts 208. As shown in FIG. 13 (where the lower one of nuts 208has been removed for purposes of illustration), the lower one of themount brackets 202 includes a slotted hole 210 which receives one of thebolts 206 and is effective for permitting vertical movement of thecondenser 14 relative to the charge air cooler 16. In contrast, brackets202 and 204 are not free to move laterally relative to one another andaccordingly, differential lateral thermal growth between condenser 14and charge air cooler 16 is accommodated by the sliding engagement ofpins 190 within grommet assemblies 160.

FIGS. 17 and 18 illustrate a cooling system 12', according to analternative embodiment of the present invention. Cooling system 12'includes a condenser 14', a charge air cooler 16' and a radiatorassembly 18 which are structurally the same, and are mounted to oneanother as described previously with respect to condenser 14, charge aircooler 16 and radiator 18 of cooling system 12, with the followingexceptions. Charge air cooler 16' includes a pair of vertically spacedpin-receiving mount means 212, which comprise a pair of verticallyspaced mount flanges, which replace the mount brackets 194 attached tothe charge air cooler 16. Each of the mount flanges 212 is preferablycast an integral unit with an outlet end manifold 60' of charge aircooler 16', for cost reduction purposes. Manifold 60' and flanges 212are preferably made of cast aluminum. End manifold 60' is otherwise thesame as manifold 60 charge air cooler 16. Condenser 14' includes a core42', having a lateral width which is greater than that of the core 42 ofcondenser 14. Brackets 202 of cooling system 12, which are attached tocondenser 14, are replaced by a pair of mount brackets 216 which arevertically spaced and attached to an end manifold 44' of condenser 14'.Also, brackets 204 of cooling system 12, which mate with brackets 202,are replaced with a pair of vertically spaced mount brackets (not shown)which are attached to charge air cooler 16' and are fastened to brackets216 so as to laterally fix end manifold 44' of condenser 14' relative tocharge air cooler 16'. Additionally, condenser 14 includes a pair ofvertically spaced pins 214 which are attached to an end manifold 46' ofcondenser 14'. One of the grommet assemblies, 160, discussed previously,is inserted through a hole formed in each of the mount flanges 212 ofcharge air cooler 16'. Each of the pins 214 are then inserted throughone of the grommet assemblies 160, with the pins 214 being free to movelaterally within the nylon inserts 162 of grommet assemblies 160. Theopposite lateral end of condenser 14' is mounted to charge air cooler16' in the same manner as that discussed previously with respect tocondenser 14 and charge air cooler 16.

In operation, condenser 14, charge air cooler 16 and radiator 72 ofradiator assembly 18 are effective for cooling the respective fluidsflowing therethrough, as a result of the ambient air 22 flowing acrossthe tubes and fins of each component. The resilient mounting of thelateral end portion of radiator 70, corresponding to end manifold 78,permits lateral thermal growth of the radiator 72 relative to the frame70 of radiator assembly 18. As the temperature of radiator 72 variesrelative to that of frame 70, leaf springs 134 deflect laterally so asto accommodate lateral thermal growth of radiator 72 relative to frame70. The use of the lower elastomeric isolators 110 and the upperelastomeric isolators 124 in the corresponding mount brackets used toattach radiator assembly 18 to the chassis of the corresponding motorvehicle isolates radiator assembly 18 from mechanical vibration loads ofthe motor vehicle. As the temperature profile of condenser 16 variesrelative to that of radiator assembly 18, the upper grommet assemblies178 may compress or expand laterally, while the lower grommet assemblies160 may expand or contract radially due to the movement of pins 158relative to brackets 154. Accordingly, differential thermal growthbetween charge air cooler 16 and radiator assembly 18 is accommodated.The engagement of pins 190, which are connected to condenser 14, withingrommet assemblies 160 permits the end manifold 46 of condenser 14 tomove laterally relative to charge air cooler 16, so as to accommodatedifferential lateral thermal growth between condenser 14 and charge aircooler 16. The foregoing discussion is also illustrative of theoperation of cooling system 20'.

While the foregoing description has set forth the preferred embodimentsof the invention in particular detail, it must be understood thatnumerous modifications, substitutions, and changes can be undertakenwithout departing from the true spirit and scope of the presentinvention as defined by the ensuing claims. The invention is thereforenot limited to specific preferred embodiments as described but is onlylimited as defined by the following claims.

What is claimed is:
 1. A Method for mounting a cooling system for use ina motor vehicle, the cooling system including a radiator assembly, acharge air cooler, and a condenser, said method comprising the stepsof:rigidly mounting a first lateral end portion of a radiator of saidradiator assembly to a support structure of said radiator assembly;resiliently mounting a second, opposite lateral end portion of saidradiator to said support structure with a resilient member which deformsto accommodate lateral thermal growth of said radiator relative to saidsupport structure during subsequent operation of the radiator in thecooling system; mounting said support structure to a chassis of saidmotor vehicle.
 2. The method as recited in claim 1, wherein said step ofresiliently mounting comprises the step of:coupling at least one springmember to said support structure and said second lateral end portion ofsaid radiator.
 3. The method as recited in claim 2, wherein said atleast one spring member comprises at least one leaf spring and whereinsaid method further comprises the step of:preloading said at least oneleaf spring.
 4. The method as recited in claim 1, further comprising thesteps of:mounting said charge air cooler to said radiator assembly so asto accommodate differential thermal growth between said charge aircooler and said radiator assembly and so as to dispose said charge aircooler in series flow relationship with said radiator assembly.
 5. Themethod as recited in claim 4, further comprising the step of:mountingsaid condenser to said charge air cooler so as to accommodate at leastdifferential lateral thermal growth between said condenser and saidcharge air cooler and so as to dispose said condenser in series flowrelationship with said charge air cooler and said radiator assembly. 6.The method as recited in claim 4, wherein said step of mounting saidcharge air cooler to said radiator assembly comprises the stepsof:attaching a pair of laterally spaced, lower mount brackets to saidradiator assembly, wherein each of said lower mount brackets includes agenerally horizontally extending portion and a hole formed therein;obtaining a first pair of compressible grommet assemblies; positioningone of said first pair of compressible grommet assemblies in each ofsaid lower mount bracket holes; attaching a pair of downwardly extendingand laterally spaced pins to said charge air cooler; inserting each ofsaid pins through one of said first pair of compressible grommetassemblies and a corresponding one of said laterally spaced lower mountbrackets so that said charge air cooler rests on said first pair ofcompressible grommet assemblies.
 7. The method as recited in claim 6,wherein said step of mounting said charge air cooler to said radiatorassembly further comprises the steps of:attaching a pair of laterallyspaced, upper mount brackets to said radiator assembly, wherein each ofsaid upper mount brackets includes a laterally facing portion and a holeformed therein; obtaining a second pair of compressible grommetassemblies; disposing one of said second pair of compressible grommetassemblies in each of said upper mount bracket holes; attaching a pairof laterally spaced, upper mount flanges to said charge air cooler,wherein each of said mount flanges includes a mount hole formed thereinwhich is aligned with said hole of one of said upper mount brackets;inserting a threaded fastener through each of said upper mount flangeholes and the corresponding ones of said second pair of compressiblegrommet assemblies; securing said threaded fasteners so as to apply aclamp load to said upper mount flanges, said second pair of compressiblegrommet assemblies and said upper mount brackets.
 8. The method asrecited in claim 7, wherein:each of said first pair of compressiblegrommet assemblies comprises a nylon sleeve having a generallycylindrical portion disposed about one of said downwardly extending pinsand an elastomeric grommet coaxially disposed about said generallycylindrical portion of said nylon sleeve; each of said second pair ofcompressible grommet assemblies comprises a generally cylindricalmetallic sleeve disposed about one of said threaded fasteners and alaterally extending elastomeric grommet coaxially disposed about saidmetallic sleeve.
 9. The method as recited in claim 5, wherein said stepof mounting said condenser to said charge air cooler comprises the stepsof:connecting a pair of vertically spaced and generally horizontallyextending pins to a first lateral end portion of said condenser;attaching a pair of vertically spaced pin-receiving mount means to saidcharge air cooler, wherein each of said mount means includes a holeformed therein which is aligned with one of said pins; disposing acompressible grommet assembly within said hole formed in each of saidmount means; inserting each of said pins through one of said grommetassemblies.
 10. The method as recited in claim 9, wherein said step ofmounting said condenser to said charge air cooler further comprises thesteps of:attaching a first pair of vertically spaced mount brackets tosaid condenser, wherein said first pair of mount brackets is laterallyspaced from said pins; attaching a second pair of vertically spacedmount brackets to said charge air cooler, wherein said first and secondpairs of vertically spaced mount brackets are aligned with one another;fastening each of said first pair of mount brackets to an aligned one ofsaid second pair of mount brackets.
 11. The method as recited in claim9, wherein said charge air cooler includes a core and a pair of endmanifolds attached to opposite lateral ends of said core and whereinsaid pair of vertically spaced pin-receiving mount means comprises firstand second vertically spaced mount brackets, and wherein said step ofattaching said pair of vertically spaced pin-receiving mount meanscomprises the steps of:attaching a first one of said mount brackets toan upper surface of said core of said charge air cooler; attaching asecond one of said mount brackets to a lower surface of said core ofsaid charge air cooler.
 12. The method as recited in claim 11, whereinsaid step of connecting said pair of vertically spaced and generallyhorizontally extending pins comprises the steps of:attaching a firstmount bracket to an upper end of said first lateral end portion of saidcondenser; attaching a second mount bracket to a lower end of said firstlateral end portion of said condenser; attaching one of said generallyhorizontally extending pins to said first mount bracket and the other ofsaid pins to said second mount bracket.
 13. The method as recited inclaim 9, wherein said charge air cooler includes a core and a pair ofend manifolds attached to opposite lateral ends of said core, whereinsaid pair of pin-receiving mount means comprises first and secondvertically spaced mount flanges and wherein said step of attaching saidpair of vertically spaced pin-receiving mount means comprises the stepof:casting said first and second vertically spaced mount flanges and oneof said end manifolds of said charge air cooler as an integral unit. 14.The method as recited in claim 13, wherein said step of connecting saidpair of vertically spaced and said generally horizontally extending pinscomprises the step of:directly attaching each of generally horizontallyextending pins to said first lateral end portion of said condenser. 15.The method as recited in claim 1, wherein said support structure of saidradiator assembly includes first and second generally U-shaped portions,and wherein said step of resiliently mounting said second lateral endportion of said radiator comprises the steps of:attaching a firstmulti-pronged mount bracket to an upper member of one of said first andsecond U-shaped portions of said support structure; attaching a secondmulti-pronged mount bracket to a lower member of said one of said firstand second U-shaped portions of said support structure; attaching afirst end of a first spring member to one of said multi-pronged mountbrackets and a second end of said first spring member to said secondlateral end portion of said radiator; attaching a first end of a secondspring member to the other of said multi-pronged mount brackets and asecond end of said second spring member to said second lateral endportion of said radiator.
 16. The method as recited in claim 15, whereinsaid first and second spring members comprise first and second leafsprings, and wherein the method further comprises the step of:preloadingsaid first and second leaf springs.
 17. The method as recited in claim16, wherein said step of preloading said first and second leaf springscomprises the step of:adjusting a position of each of said multi-prongedbrackets relative to said one of said first and second U-shaped portionsof said support structure of said radiator assembly.
 18. The method asrecited in claim 16, further comprising the step of:connecting saidfirst and second U-shaped portions of said support structure of saidradiator assembly.
 19. The method as recited in claim 16, wherein saidstep of rigidly mounting said first lateral portion of said radiatorcomprises the step of:fastening said first lateral end portion of saidradiator to the other of said first and second U-shaped portions of saidsupport structure of said radiator assembly.